GB2219548A - Mould for cellular concrete - Google Patents

Mould for cellular concrete Download PDF

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Publication number
GB2219548A
GB2219548A GB8819988A GB8819988A GB2219548A GB 2219548 A GB2219548 A GB 2219548A GB 8819988 A GB8819988 A GB 8819988A GB 8819988 A GB8819988 A GB 8819988A GB 2219548 A GB2219548 A GB 2219548A
Authority
GB
United Kingdom
Prior art keywords
mould
cellular concrete
heat
warm
insulating
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB8819988A
Other versions
GB8819988D0 (en
Inventor
Mikio Hihara
Nobuhisa Suzuki
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nissei Plan Inc
Original Assignee
Nissei Plan Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP63143075A external-priority patent/JPH022001A/en
Priority claimed from JP63143076A external-priority patent/JPH01313373A/en
Application filed by Nissei Plan Inc filed Critical Nissei Plan Inc
Publication of GB8819988D0 publication Critical patent/GB8819988D0/en
Publication of GB2219548A publication Critical patent/GB2219548A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/50—Producing shaped prefabricated articles from the material specially adapted for producing articles of expanded material, e.g. cellular concrete
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/50—Producing shaped prefabricated articles from the material specially adapted for producing articles of expanded material, e.g. cellular concrete
    • B28B1/503—Moulds therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/0088—Moulds in which at least one surface of the moulded article serves as mould surface, e.g. moulding articles on or against a previously shaped article, between previously shaped articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/34—Moulds, cores, or mandrels of special material, e.g. destructible materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/40—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material
    • B28B7/42—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material for heating or cooling, e.g. steam jackets, by means of treating agents acting directly on the moulding material
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B22/00—Use of inorganic materials as active ingredients for mortars, concrete or artificial stone, e.g. accelerators, shrinkage compensating agents
    • C04B22/02—Elements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B22/00—Use of inorganic materials as active ingredients for mortars, concrete or artificial stone, e.g. accelerators, shrinkage compensating agents
    • C04B22/02—Elements
    • C04B22/04—Metals, e.g. aluminium used as blowing agent
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/0082—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability making use of a rise in temperature, e.g. caused by an exothermic reaction
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S264/00—Plastic and nonmetallic article shaping or treating: processes
    • Y10S264/43—Processes of curing clay and concrete materials

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Moulds, Cores, Or Mandrels (AREA)
  • On-Site Construction Work That Accompanies The Preparation And Application Of Concrete (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

A mould 10 for use in the manufacture of cellular concrete comprises a plurality of stacked mould units 13 each having a heat-insulating base 11 and casing 12; a heat-insulating top board 16; and a base-to-casing joint. A process for the manufacture of cellular concrete comprises: mixing cement with warm water at a temperature of 40 to 75 DEG C to form a warm cement mortar; mixing the mortar with a bubbled warm frother solution to form a warm cellular concrete paste; and hardening the paste using the heat-insulating mould 10. <IMAGE>

Description

MOULD FOR CELLULAR CONCRETE AND A PROCESS FOR ITS MANUFACTURE This
invention relates to a mould for cellular concrete and a process for the manufacture of cellular concrete.
As cellular concrete is light weight, has good fire resistance and good sound insulating and heat insulating properties, it has found a definite niche in the field of building material.
There are two main processes for producing cellular concrete: (1) manufacture of a cement mortar foam in a mould after mixing all the ingredients and (2) mixing a cement mortar with a bubbled frother solution, followed by casting this cellular concrete paste into a mould to solidify. The latter process is widely used as it facilitates the manufacture of cellular concrete in a particular shape. The present invention relates to this process.
The increasing demand for cellular concrete has urged the skilled man to find a process for its rapid manufacture and at lower costs. For this reason, the use of "earlystrength" cement or processes for hardening cellular concrete in a housing having an elevated temperature have been proposed, to shorten the hardening time. However, these processes have not been able to lower production costs of cellular concrete satisfactorily. The cost of "early strength" cement is still expensive. Further, the construction of the housing for keeping the cellular concrete at elevated temperatures is expensive as is the cost of fuel for heating.
In accordance with a first aspect of the present invention there is provided, a mould for cellular concrete which comprises: one or more mould units capable of being stacked on upon the other, each mould unit comprising a heat-insulating base and casing; and a heat-insulating top board.
In use a number of mould units are stacked on each other and covered with the heat-insulating top board, to retain the elevated temperature of the cellular concrete.
A reagent capable of undergoing exothermic reactions with water or oxygen may be added and is effective at keeping the elevated temperature of the cellular concrete in the mould.
For a better understanding of the present invention, and to show how the same may be put into effect, reference will be made to the drawings, in which:
Figure 1 is a perspective, schematic view of a mould according to the present invention; Figure 2 is a sectional detail of the heat insulating base and casing of the mould of Figure 1; Figure 3 is a detail of a base-to-casing joint of the mould of Figure 1; Figure 4 is a plan view of a mould unit having a partition; and Figure 5 is a mixer unit which was used in the preparation of cellular concrete to be tested.
A mould (10) according to the present invention comprises a plurality of substantially rectangular mould units (13) which in turn comprise a substantially rectangular hollow casing (12) of a heat-insulating material and a substantially rectangular base (11) also of a heat-insulating material, which are alternatingly stacked, starting with a base (11), one on top of the other to form a stack of mould units (13) each possessing a base (11) and a casing (12). Each base (11) is provided with four connecting members which extend outwards and sideways from the base (11) two at each of its shorter sides, and each of which connecting member is provided with an aperture (18). Each casing (12) is provided with four corresponding connecting members, which extend outwards and downwards from the casing (12) two at each of its shorter sides and which are also each provided with an aperture (18). The arrangement being such that when a base (11) is stacked upon a casing (12) the apertures (18) of corresponding connecting members are aligned. Each base (11) and casing (12) may be joined by means of a bottom- tocasing joint member (19), one end of which extends through the aligned apertures (18) of the base (11) and casing (12) and the other end of which forms a substantially U-shaped bend which encompasses the corresponding connecting members between the limbs of the U-shaped bend.
Situated uppermost in the mould (10), upon the stack of mould units (13) is a top board (16) of a heat insulating material.
As shown in Figures 2 and 4, the base (11) and casing (12) are formed of walls of protective material (15), such as a metal, enclosing a heat insulating material (14), such as foam plastic board.
As shown in Figure 4, the individual mould units (13) of the mould (10) may be divided into smaller areas using heat-insulating partitions (17) and/or a facing material (21) may be placed on top of the base prior to casting the cellular concrete paste into the mould unit (13).
The following Examples are illstrative of preferred ways of using a mould according to the present invention, for the manufacture of cellular concrete.
In the following Examples, cellular concrete was prepared using a mixer unit as shown in Figure 5.
Example 1
In advance, the whole mixer unit was warmed by passing hot water through the unit. Into a first mixer (3) were fed 360 kg of Portland cement (Nippon Cement Co.) from a cement inlet (4) and 200 kg of warm water at a temperature of 600 from a water inlet (5). The mixture was blended for 2 minutes and transferred through the connection (6) into a second mixer (7). At the same time, 20 kg of a warm frother solution (1.0 kg of a sulfate of higher alcohol, Foamix C:Hamano Kogyo Co., in 19 kg of water), which had been aerated by a bubble generator at a temperature of 600C, was fed from a frother inlet (9) into the second mixer (7). The mixture was blended for 5 minutes and cast into a mould unit (13) as shown in Figure 1. At this time, the temperature of the cellular concrete paste was 550C, as determined by an L-type thermometer inserted into the centre of the product. Individually filled mould units (13) were stacked as shown in Figure 1, and allowed to stand for 5 hours at room temperature, and then the cellular concrete was r'emoved from the mould. The temperature of the product 5 hours after the casting was found to be 420C. Example 2 Cellular concrete was prepared in the same manner as given in Example 1, except that 50 g of zirconium was added into the second-mixer (7) from an inlet (20) during the addition of the warm bubbled frother solution. Control 1 Cellular concrete was prepared in the same manner as given in Example 1, except that a prior art mould having no heat-insulating walls was used.
The temperature'and flexural strength of the cellular concrete prepared in which case was compared, 5 hours after the casting. The procedures and moulds, and results, are given in the folowing Tables 1 and 2, respectively.
Table 1
Test No. Zirconium Mould Example A none According to the present invention, as shown in Figure 1 Example B 50 g According to the present invention, as shown in Figure 1 Control 1 none Prior art, without insulation Table 2
Test No. Temperature Flexural Strength Casting 5 hours (kg/cm2) after 5 hours after Example A 550C 420C 0.4 Example B 550C 470C 0.5 Control 1 550C 280C 0.1 Example 3
Cellular concrete paste was prepared in the same manner as described in Example 1, except that the paste was cast into a partitioned mould unit, as shown in Figure 4. Prior to the casting, a facing material (21) was laid on the base (11), as shown in Figure 4. Individual mould units containing the cellular concrete paste and facing material were stacked in the manner shown in Figure 1, and allowed to stand for 5 hours at room temperature. At this stage, the cellular concrete was stuck to the facing material. The cellular concrete attached to the facing material was taken out from the mould and dried for 1 month at room temperature. It was found that the product was sufficiently serviceable.
The improvement in cellular concrete prepared using a mould and process according to the present invention as compared to that produced with the control mould is evident from the above data.
1

Claims (9)

1. A mould for cellular concrete which comprises one or more mould units capable of-being stacked one upon the other, each mould unit comprising a heat- insulating base and easing; and a heat-insulating top board.
2. A mould according to claim 1, wherein the base and casing of the mould unit are connected by a base-to-casing joint member.
3. A mould according to claims 1 or 2, wherein the mould unit is provided with a heat-insulating partition.
4. A mould according to claims 1, 2 or 3, wherein each of the heat-insulating base. casing and is top board has a structure wherein a heat-insulating material is covered with a protective material.
5. A mould according to claim 4, wherein the heat-insulating material is a foam plastic board and the protective material is a metal.
6. A moulding device substantially as hereinbefore described with reference to, and as illustrated in Figures 1, 2 and 3; or Figure 4 of the accompanying drawings.
7. A process for the manufacture of cellular concrete which comprises: mixing cement with warm water at a temperature in the range 40 to 75 0 C to form a warm cement mortar; mixing the mortar with a warm bubbled frother solution to form a warm cellular concrete paste; and hardening the paste in a mould as claimed in claim 1.
8. A process according to claim 7, wherein a reagent capable of undergoing an exothermic reaction with water or oxygen is added into the warm cement mortar together with a bubbled warm frother solution.
9. A process according to claim 8, in which the reagent is zirconium.
- - -:7 - - 1 1-1
GB8819988A 1988-06-10 1988-08-23 Mould for cellular concrete Withdrawn GB2219548A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP63143075A JPH022001A (en) 1988-06-10 1988-06-10 Apparatus for preparing concrete product
JP63143076A JPH01313373A (en) 1988-06-10 1988-06-10 Production of exterior material made of strengthened aerated concrete

Publications (2)

Publication Number Publication Date
GB8819988D0 GB8819988D0 (en) 1988-09-21
GB2219548A true GB2219548A (en) 1989-12-13

Family

ID=26474889

Family Applications (1)

Application Number Title Priority Date Filing Date
GB8819988A Withdrawn GB2219548A (en) 1988-06-10 1988-08-23 Mould for cellular concrete

Country Status (3)

Country Link
US (1) US5110084A (en)
KR (1) KR920009531B1 (en)
GB (1) GB2219548A (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106217619A (en) * 2016-09-26 2016-12-14 安徽倍立达住工科技有限公司 A kind of foam cement board forming die and preparation cement board method thereof

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US5228946A (en) * 1991-12-17 1993-07-20 E. I. Du Pont De Nemours And Company Multi-plate lamination fixture
US6676862B2 (en) * 1999-09-15 2004-01-13 Advanced Building Systems, Inc. Method for forming lightweight concrete block
WO2001019579A1 (en) * 1999-09-15 2001-03-22 Air Crete Block, Inc. Method and apparatus for forming lightweight concrete block
CH703868B1 (en) 2010-09-16 2016-06-15 Creabeton Matériaux Sa Building material and construction system element and method of making same.
KR102226451B1 (en) * 2014-09-22 2021-03-12 에스케이하이닉스 주식회사 Apparatus for cleaning the substrate carrier and method for claeaning thereof

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106217619A (en) * 2016-09-26 2016-12-14 安徽倍立达住工科技有限公司 A kind of foam cement board forming die and preparation cement board method thereof
CN106217619B (en) * 2016-09-26 2019-04-09 安徽倍立达住工科技有限公司 A kind of foamed cement board forming die and its preparation cement board method

Also Published As

Publication number Publication date
US5110084A (en) 1992-05-05
GB8819988D0 (en) 1988-09-21
KR920009531B1 (en) 1992-10-19
KR900000174A (en) 1990-01-30

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